Integrated 3-D blade structure

ABSTRACT

An integrated 3-D blade structure which consists of at least two integrated pieces made by one-time shaping. Each integrated piece has several shorter 3-D curved-face blades and the relative let-in structures. Via the said let-in structures, it is easily to match with the two integrated pieces at least. Then, the plural shorter blades could be matched with adjacent blades each other depending on different design and to form a complete 3-D curved-face blade, or keeping a little distance between the matching blades to become a “Multi-Row” blade structure. Originally, since the whole blade structure with complicate 3-D curved face has been divided to several shorter blades for manufacturing, they are made via plastic emergence with forming or wax forming. Therefore, not only the element amount is highly decreased, but also the cost for position and assembly of blades is going down. Furthermore, the goal to approach the “Multi-Row” diffuser and impeller made via plastic emergence with forming or wax forming could be successful.

FIELD OF THE INVENTION

[0001] This invention relates the integrated blades with 3-D structure,especially the 3-D blades structure of centrifugal impellers ordiffusers to pumps, blowers, etc.

BACKGROUND OF THE INVENTION

[0002] Generally, the impellers and diffusers in pumps or blowers are3-D and metal-plate blades. These blades are mostly used by highefficiency centrifugal pumps and it is due to that the blades haveexcellent 3-D curved faces which can be corresponding with the angles orloading distribution of fluid on impellers or diffusers' runners. Suchthat, pumping efficiency will be highly promoted.

[0003] Because of the 3-D curved faces with runners of blades, thefigures of the curved faces will be hardly manufactured by usingtechnologies of casting with pattern and plastic emergence with patterndraw. Therefore, generally, present manufacturing method is to formintegrally blades (means plural blades could be formed integrally), butit is only for 2-D curved blades and not for perfect 3-D curved faces.Due to simple blade angles are not matched fluid angles and loadingrequired, pump efficiency shall be highly coming down, and such caseonly fits with centrifugal pumps which are cheap and low efficiency.

[0004] Prior art manufacturing technologies could make nice and 3-Dcurved faces of blades. On the other hand, large amount of blades,complicate design, hardly to position in detail for 3-D impellers, etc.are the short points for prior art technologies. Thus, firstly,manufacturing blades piece by piece via wax is the only method for priorart method. Then, to position blades in front of impellers and betweenback covers, and following with pour for finishing casting. Or,manufacturing blades piece by piece via plastic emergence with formingand positioning these blades separately to the places before impellersand between back covers for a whole set of impeller. As the processesfor manufacturing impellers and diffusers via plastic emergence andcasting mentioned above, they are very complicate and not on theeconomical point.

[0005] Besides, for some special designs of pumps, such as focusing onpumping functions of de-swirl of diffuser runner, or promoting pumpingefficiency. The prior art technologies are taking impellers or diffuserswith “Multi-Row” structures. For example, the patent of TaiwanPublication Number 342425, U.S. Pat. Nos. 5,310,309, 4,877,370,5,417,547, 5,516,263, 4,354,802, etc. are discussing “Multi-Row” bladestructures for applications and approaches. Nevertheless, these priorart 3-D curved and “Multi-Row” blade structures made by punchingmetal-plate will be manufactured, positioned and assembled piece bypiece, and this kind of structure will increase multiple blades.Therefore, the assembly difficulty and manufacturing cost could behighly increased. Thus, such technology still needs some advanced skill.

SUMMARY OF THE INVENTION

[0006] The first object of the invention is to supply an integrated 3-Dblade structure. Originally, the technology for blades is tomanufacture, position and assemble separately, but now, the processescan be coordinated to a few of integrated pieces for once of plasticemergence with forming or wax for entire structure. Such that, the onlyway is to combine those few integrated pieces and finish position,assembly or further work of blades simultaneously. The profits for thecombination mentioned above are not only that each blade has nice 3-Dcurved face and highly promoted pumping efficiency, but also greatlydecreasing the difficulty of positioning and assembly and the cost ofwhole manufacturing.

[0007] The second object is to supply an integrated 3-D blade structurevia that coordinating a large amount of blades to a few of pieces whichcan be formed by once of plastic emergence with forming or wax forentire structure. The only way is to combine the few pieces and the“Multi-Row” blade structure can be assembled rapidly. The profits fromthe combination technology are that having nice 3-D curved face andhighly promoted pumping efficiency for each blade and simplifying theprocesses of assembly and decreasing cost.

[0008] To approach the above objects, the preferred embodiment for theintegrated 3-D blade structure of the invention is including at leasttwo integrated pieces that are formed in one time. Each integrated piecehas plural blades of shorter 3-D curved faces and relative let-instructure. It is easily assembling at least two integrated pieces viathe let-in structure, and the shorter blades can be adjacent relativelyto form complete 3-D curved face depending on different design or keep asuitable distance in between to form a “Multi-Row” blade structure.Originally, a complete blade with complicate 3-D curved face could bedivided to several shorter lengths for manufacturing, thus the bladecould be assembled and formed by plastic emergence with forming or waxforming. Therefore, resulting to that the amount of components is highlydecreased and the position and assembly for blades are more convenientand cost is also down. Furthermore, the impeller and diffuser with“Multi-Row” can be made by plastic or casting.

[0009] For fully understanding this invention with features and content,the following examples with detail drawings will let you have furtherunderstanding for advantages and applications of this invention.

BRIEF DESCRIPTION OF DRAWINGS

[0010]FIG. 1A is the front view of inner piece of preferred embodimentfor this invention.

[0011]FIG. 1B is the sectional view of FIG. 1A (along line 91-91).

[0012]FIG. 2A is the front view of outer piece of preferred embodimentfor the invention.

[0013]FIG. 2B is the sectional view of FIG. 2A (along line 92-92).

[0014]FIG. 3A is the front view of impeller hub center of preferredembodiment for this invention.

[0015]FIG. 3B is the sectional view of FIG. 3A (along line 93-93).

[0016]FIG. 3C is the rear view of FIG. 3A.

[0017]FIG. 4 is the sectional view of impeller front cover structure ofpreferred embodiment for this invention.

[0018]FIG. 5A is the front view of outer diffuser hub structure ofpreferred embodiment for this invention.

[0019]FIG. 5B is the sectional view of FIG. 5A (along line 95-95).

[0020]FIG. 5C is the rear view of FIG. 5A.

[0021]FIG. 6A is the front view of inner diffuser of preferredembodiment for this invention.

[0022]FIG. 6B is the sectional view of FIG. 6A (along line 94-94).

[0023]FIG. 7 is the sectional view of assembled hub structure ofpreferred embodiment for this invention.

[0024]FIG. 8 is the sectional view of elements relative positionsassembly of preferred embodiment for this invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0025] The main feature is that giving up the prior art method tomanufacture centrifugal pumps and blowers via plastic or casting forimpellers or diffusers, and firstly, the processes of the method is toform each blade individually, thus, to position, assemble and combinethe whole impeller step by step. In contrast, this invention is tointegrate two or more integrated pieces and such pieces are dividedplural pieces (more than six as usual) for individually manufacturing asoriginal. Thus, all we have to do is that combining the said twointegrated pieces and the position for multiple blades, assembly or morework can be completed simultaneously. Furthermore, the impeller ordiffuser with “Multi-Row Blades” structure could be developed. Eachintegrated piece has multiple shorter blades and 3-D curved face made byplastic emergence with forming or wax forming. After combining the saidtwo or more integrated pieces, the blades of the pieces can form asingle blade with curved face, or the blades are not adjacent but theblade structure with multi-row still can be formed by them. Thisinvention divides blades with 3-D curved faces to several differentparts and figures out the difficulty of prior art technology formanufacturing. Hence, the possibility for plastic emergence with formingor wax forming to form blades with 3-D curved faces is created. Usingthis method and structure, the element amount of impeller or diffuserwill be highly decreased, and assembly for blades are more convenientand cost is also down. Further, the cost is not only including mold, butalso clamping apparatus. The runner design for impeller or diffuser ismore flexible from this invention, and plastic emergence with forming orcasting for forming the impeller and diffuser with “Multi-Row Blades”can be reached.

[0026] Firstly, referring to FIG. 1A to FIG. 4, the impeller of theintegrated 3-D blade structure with plastic or wax made is the preferredembodiment. For the preferred embodiment, the said impeller with 3-Dplastic or wax blades consists of a first integrated piece (called innerpiece 1 for following) and a second integrated piece (called outer piece2 for following). The said two pieces are made of plastic emergence withforming or wax forming and having plural blades individually. Anotherpoint, this preferred embodiment divides the 3-D plastic or wax bladesof the impeller to two parts of piece 1 and piece 2 for manufacturing.Also, the said blades of the impeller could be divided three or morepieces.

[0027] Please refer to FIG. 1A and FIG. 1B. The said inner piece 1 is ahollow and disc shape, and there are some shorter 3-D inner blades 10(about a half length of normal blade) and also they are radiateelongation. Each 3-D inner blade 10 has its own 3-D curved face and canbe made by plastic emergence with forming or wax forming because ofshorter length and no overlap of adjacent blades. From the closer innerend of each inner blade 10, the arrangement in order is inner base plate11 and inner blade body 12. The central part of inner base plate 11 is ahub hole 16 going through the said inner base plate 11 and the rim ofinner base plate 11 is let-in edge 15. The let-in edge 15 for thispreferred embodiment is a straight-line edge structure, but it could beother geometry structures. The inner leading edge 13 and the innertrailing edge 14 are defined as the two ends of inner blade body 12.Between inner blade body 12 and inner base plate 11 is an angle that isa 3-dimention structure.

[0028] Referring to FIG. 2A and FIG. 2B, outer piece 2 is a hollow anddisc shape, and there are some 3-D outer blades 20 and also they areradiate elongation. From the closer inner end of each outer blade 20,the arrangement in order is outer base plate 21 and outer blade body 22.The central part of outer base plate 21 is a let-in hole 25 goingthrough the said outer base plate 21 and the shape of outer base plate21 is for let-in edge 15 to let-in and position. Between outer bladebody 21 and outer base plate 21 is an angle that is a 3-dimentionstructure. The outer leading edge 23 and the outer trailing edge 24 aredefined as the two ends of outer blade body 21.

[0029] Referring to FIGS. 3A, 3B and 3C, it is a blade center hub body 3and made by plastic emergence with forming and wax forming. The centralpart of the blade center hub body 3 is hub piercing 34 and severalimpeller blade grooves 33 which are radiate elongation at the side ofthe blade center hub body 3. The central part is a hollow cylinder andtoward left from view FIG. 3B and can form a blade hub 31. On the otherside, the center is a flat face and elongates toward left from view FIG.3B to form a hollow cylinder, thus the diffuser hub 32 is ready.

[0030] Referring to FIG. 4, it is a sectional view of structure ofimpeller front cover 4. The said impeller front cover 4 is made byplastic emergence with forming or wax forming and it is a hollow andbonnet shape structure. The top of bonnet is a hollow cylinder withsuitable thickness; hence the fixing hub 41 is formed.

[0031] When let-in edge 15 of inner piece 1 matching with let-in hole 25of outer piece 2, the two pieces 1 and 2 could be combined to integrated3-D blade structure rapidly. The combination for inner piece 1 and outerpiece 2 is via hub hole 16, and blade hub 31 and outer blades 20 are setto impeller blade grooves 33 to become a whole body. After that, tocombine and position inner piece 1 and outer piece 2 in between impellerfront cover 4 and blade center hub body 3 and therefore forming acomplete impeller structure. Such this, to easily and rapidly theassembling work for the complete impeller structure is absolutely no anyproblem for positioning blades.

[0032] For the preferred embodiment, the inner trailing edges 14 ofinner blades 10 in inner piece 1 are matched to relative and adjacentouter leading edges 23 of outer blades 20 in outer piece 2 individually.Therefore, the complete blade structure is with nice 3-D curved face andthe pumping efficiency can be promoted. On the other hand, it is easilyto think about that after assembling inner trailing edges 14 and outerleading edges 23, keeping a little distance between them will become a“Multi-Row” blade structure. Besides, the number of inner blades 10 isequal to the number of outer blades 20 in the preferred embodiment andthe different numbers for both also can be made.

[0033] Referring to FIG. 5A and FIG. 5B, the preferred embodiment is anintegrated 3-D impeller structure applied to diffuser made by plastic orwax. The 3-D blades of the said diffuser in the preferred embodimentconsist of a first integrated piece and a second integrated piece. Thesaid two integrated pieces are made via plastic emergence with formingor wax forming, and have several diffuser blades. Although the 3-Ddiffuser blades are divided to two parts that are outer diffuser hub 5and inner diffuser 6, and three or more parts also can be made.

[0034] Referring to FIG. 5A, FIG. 5B and FIG. 5C, the outer ring hub 58of the outer diffuser hub 5 is a ring figure structure and the saidouter ring hub 58 connects with 3-D outer diffuser blades 50 which areradiate elongation. The arrangement of closer inner end of each outerdiffuser blade 50 in order is an outer base plate 51 and outer diffuserblade body 52. There is a bulging cylinder arranged on central part ofthe outer base plate 51 and a diffuser hub hole 57 on the center ispenetrating the outer diffuser hub 5. Thus, the outer hub 56 is formedand there are some radiate elongation inner diffuser grooves 55 from theouter hub 56. Between outer diffuser blades 50 and outer base plates 51are suitable angles that are 3-D structures. The outer diffuser leadingedges 53 and outer diffuser trailing edges 54 are defined at the twoends of outer base plate 51.

[0035] As FIG. 6A and FIG. 6B showing, the inner diffuser 6 is a discshape with hollow structure, and there are several radiate elongation3-D inner diffuser blades 60 arranged on the inner diffuser 6. Thearrangement of closer and inner end of each inner diffuser blade 60 inorder is an inner base plate 66, an inner diffuser bottom plate 62 andan inner diffuser body 63. The center of the inner base plate 66 is aninner hub hole 67 penetrating the inner diffuser 6 and the position ofthe inner hub hole 67 is opposite to the outer hub 56. Between innerdiffuser bodies 63 and inner diffuser bottom plates 62 are suitableangles that are 3-D structures. The inner diffuser leading edge 64 andthe inner diffuser trailing edge 65 are defined at the two ends of eachinner diffuser body 63.

[0036] When assembling, to combine and position the outer hub 56 of theouter diffuser hub 5 and the inner hub hole 67 of the inner diffuser 6,and to match the inner diffuser bottom plate 62 with the inner diffusergroove 55 of the outer base plate 51. Such that, the integrated 3-Dblade structure is formed. Following the above assembling process, anassembling work for a complete diffuser structure is easily and rapidly,and there is no problem for plural diffuser blades to position andassembling.

[0037] When outer diffuser hub 5 combining with inner diffuser 6 in thepreferred embodiment, the outer diffuser trailing edges 54 of outerdiffuser blades 50 are individually relative to the inner diffuserleading edges 64 of inner diffuser blades 60. Each pair of outerdiffuser trailing edge 54 and inner diffuser leading edge 64 is stillkeeping a little distance between them on radius or circumferencedirection and in order to become a “Multi-Row” blade structure. On theother hand, the design can be changed to that combining outer diffusertrailing edges 54 and inner diffuser leading edges 64 to plural one-bodyblades for the diffuser structure. Although the number of outer diffuserblades 50 is same as the number of inner diffuser blades 60, otherdifferent numbers between them also can be made.

[0038] As FIG. 7 showing, it is a binding hub 7 made by plasticemergence with forming or wax forming and multiple layers with hollowring shape structure. From center, the arrangement in order is a fixinghub hole 71, a placing hole 72 and an outer ring 73. The outside of theouter ring 73 is set a flange ring 74 for matching binding hub 7 withouter diffuser hub 5. Hence, a room 75 is between them.

[0039] As FIG. 8 showing, it is the sectional view of elements relativepositions assembly of preferred embodiment for this invention. Thebinding hub 7 is combining with outer ring hub 58 of outer diffuser hub5 via outer ring 73, and flange ring 74 is matching with outer diffuserhub 5, therefore, one side is left room 75 because of matching withdiffuser hub 5 and the other side is matching with another diffuser hub5. Following the combination will be no limitation for extensioncombination and it can be suitable for different outputs.

[0040] The room 75 is just making impeller to let-in. Thus, thecombination is as that fixing hub hole 71 is matching with fixing hub 41of impeller front cover 4, and blade center hub body 3 is penetrating todiffuser hub hole 57 of outer diffuser hub 5, thus the purposes toposition and combine are reached.

[0041] As the preferred embodiment of the invention, elements are madevia plastic emergence with forming or wax forming, and therefore toinstall them depending on design. By using plastic is because of theflexible feature and the elements are combine tightly to reach theexpected efficiency. When casting, to combine those wax forms of pluralpieces and the complete wax form can be finished. After, pouring for thecomplete wax form could decrease the short point of a large amount ofelements for prior art technology.

[0042] It may thus be seen that the objects of the present invention setforth herein, as well as those made apparent from the foregoingdescription, are efficiently attained. While the preferred embodimentsof the invention have been set forth for purpose of disclosure,modifications of the disclosed embodiments of the invention as well asother embodiments thereof may occur to those skilled in the art.Accordingly, the appended claims are intended to cover all embodiments,which do not depart from the spirit and scope of the invention.

What is claimed is:
 1. An integrated 3-D blade structure which consistsof: an inner piece which is hollow and disc, and there are some 3-Dinner blades which are radiate elongation, from the closer inner end ofeach inner blade, the arrangement in order is inner base plate and innerblade body, the central part of inner base plate is a hub hole goingthrough the said inner base plate, and the rim of inner base plate islet-in edge, between inner blade body 12 and inner base plate 11 is anangle that is a 3-dimention structure, and the inner leading edge 13 andthe inner trailing edge 14 are defined as the two ends of inner bladebody; an outer piece is a hollow and disc shape, and there are some 3-Douter blades and also they are radiate elongation, from the closer innerend of each outer blade, the arrangement in order is outer base plateand outer blade body, the central part of outer base plate is a let-inhole going through the said outer base plate and the shape of outer baseplate is for let-in edge to let-in and position, between outer bladebody and outer base plate is an angle that is a 3-dimention structure,the outer leading edge and the outer trailing edge are defined as thetwo ends of outer blade body; the let-in edge of inner piece matchingwith let-in hole of outer piece, the two pieces could be combined to anintegrated 3-D blade structure.
 2. An integrated 3-D blade structure ofclaim 1, wherein the inner piece is made by one of the following method:plastic emergence with forming and wax forming.
 3. An integrated 3-Dblade structure of claim 1, wherein the outer piece is made by one ofthe following method: plastic emergence with forming and wax forming. 4.An integrated 3-D blade structure of claim 1, wherein, in case of thetwo pieces combining into one, the inner trailing edges of inner bladesin inner piece are matched to relative and adjacent outer leading edgesof outer blades in outer piece individually, and the complete bladestructure is completed.
 5. An integrated 3-D blade structure of claim 1,wherein, in case of the two pieces combining into one, the innertrailing edges of inner blades in inner piece are matched to relativeand adjacent outer leading edges of outer blades in outer pieceindividually, and after assembling each pair of edges, keeping a littledistance between them will become a “Multi-Row” blade structure.
 6. Anintegrated 3-D blade structure of claim 1, wherein, consisting of: animpeller front cover, which is a hollow and bonnet shape structure, andthe top of bonnet is a hollow cylinder with suitable thickness; hence afixing hub is formed; and an blade center hub body, the central part ofthe said blade center hub body is hub piercing and several impellerblade grooves which are radiate elongation at one side of the bladecenter hub body, the central part is a hollow cylinder and toward leftfrom view direction and can form a blade hub, on the other side, thecenter is a flat face and elongates toward left from view direction toform a hollow cylinder, thus the diffuser hub is ready, the inner pieceand the outer piece combined and positioned between the said impellerfront cover and the blade center hub body is to form a complete bladestructure.
 7. An integrated 3-D blade structure of claim 6, wherein, theimpeller front cover is made by one of the following method: plasticemergence with forming and wax forming.
 8. An integrated 3-D bladestructure of claim 6, wherein, the blade center hub body is made by oneof the following method: plastic emergence with forming and wax forming.9. An integrated 3-D blade structure of claim 1, wherein, the let-inedge is a straight-line edge structure.
 10. An integrated 3-D bladestructure which consists of: an outer diffuser hub, wherein, an outerring hub 58 is a ring figure structure and the said outer ring hubconnects with 3-D outer diffuser blades which are radiate elongation,the arrangement of closer inner end of each outer diffuser blade inorder is an outer base plate 51 and outer diffuser blade body, there isa bulging cylinder arranged on central part of the outer base plate anda diffuser hub hole on the center is penetrating the outer diffuser hub,thus, the outer hub is formed and there are some radiate elongationinner diffuser grooves from the outer hub, between outer diffuser bladesand outer base plates are suitable angles that are 3-D structures, theouter diffuser leading edges and outer diffuser trailing edges aredefined at the two ends of outer base plate; an inner diffuser, which isa disc shape with hollow structure, and there are several radiateelongation 3-D inner diffuser blades arranged on the inner diffuser, thearrangement of closer and inner end of each inner diffuser blade inorder is an inner base plate, an inner diffuser bottom plate and aninner diffuser body, the center of the inner base plate is an inner hubhole penetrating the inner diffuser and the position of the inner hubhole is opposite to the outer hub, between inner diffuser bodies andinner diffuser bottom plates are suitable angles that are 3-Dstructures, the inner diffuser leading edge and the inner diffusertrailing edge are defined at the two ends of each inner diffuser body;by assembling, to combine and position the outer hub of the outerdiffuser hub and the inner hub hole of the inner diffuser, and to matchthe inner diffuser bottom plate with the inner diffuser groove of theouter base plate, and therefore the integrated 3-D blade structure isformed.
 11. An integrated 3-D blade structure of claim 10, wherein, theouter diffuser hub is made by one of the following method: plasticemergence with forming and wax forming.
 12. An integrated 3-D bladestructure of claim 10, wherein, the outer diffuser hub is made by one ofthe following method: plastic emergence with forming and wax forming.13. An integrated 3-D blade structure of claim 10, wherein, the outerdiffuser hub combines with inner diffuser and the outer diffusertrailing edges of outer diffuser blades are individually relative to theinner diffuser leading edges of inner diffuser blades, each pair ofouter diffuser trailing edge and inner diffuser leading edge is stillkeeping a little distance between them on radius or circumferencedirection and in order to become a “Multi-Row” blade structure.
 14. Anintegrated 3-D blade structure of claim 10, wherein, the outer diffuserhub combines with inner diffuser and the outer diffuser trailing edgesof outer diffuser blades are individually relative to the inner diffuserleading edges of inner diffuser blades, each pair of outer diffusertrailing edge and inner diffuser leading edge is combining outerdiffuser trailing edges and inner diffuser leading edges to pluralone-body blades for the diffuser structure.
 15. An integrated 3-D bladestructure of claim 10, wherein, the number of the outer diffuser bladeof the outer diffuser hub is different than the number of inner diffuserblade of the inner diffuser.
 16. An integrated 3-D blade structure ofclaim 10, wherein, the number of the outer diffuser blade of the outerdiffuser hub is same with the number of inner diffuser blade of theinner diffuser.
 17. An integrated 3-D blade structure of claim 10,wherein, furthermore, a binding hub is a multiple layers with hollowring shape structure, from center, the arrangement in order is a fixinghub hole, a placing hole and an outer ring, the outside of the outerring is set a flange ring for matching the said binding hub with theouter diffuser hub, hence, a room is between them.
 18. An integrated 3-Dblade structure of claim 17, wherein, the binding hub is made by one ofthe following method: plastic emergence with forming and wax forming.19. An integrated 3-D blade structure which consists of: a firstintegrated piece, which has some first blades and they are radiateelongation and three dimensional, and a predetermined let-in edge; asecond integrated piece, which has some first blades and they areradiate elongation and three dimensional, and a predetermined let-inhole which is for the said let-in edge to let-in and position; thelet-in edge of first integrated piece matching with let-in hole of thesecond integrated piece, the two pieces could be combined to anintegrated 3-D blade structure.
 20. An integrated 3-D blade structure ofclaim 19, wherein, the first integrated piece is combining with thesecond integrated piece, each blade of the first integrated piece isindividually relative and adjacent with the second integrated piece'sblades, and then to form plural one-body curved face blades and the saidblades are certainly three dimensional.
 21. An integrated 3-D bladestructure of claim 19, wherein, the first integrated piece is combiningwith the second integrated piece, each blade of the first integratedpiece is individually keeping a little distance to relative blade of thesecond integrated piece, and then to form a “Multi-Row” blade structure.